Large area sintering test platform and associated method of use

Abstract

A large area sintering platform, system, and methodology. The system includes a convection oven with a projection window disposed within a top surface of the oven. A platform is disposed within the oven below the window at a spaced distance away from the window. A powder is positioned on top of the platform, with a thermocouple positioned within the powder on the platform. A high intensity projector moves in sync with the platform, and uses low intensities and long exposure times to project an image through the window onto the powder and sinter the powder to fabricate the desired model layer by layer.

What is claimed is: 
     
       1. A system for sintering a powder comprising:
 a projector having a predetermined image area to heat up and sinter a predetermined cross section of a powder layer; 
 a thermal camera configured to measure a temperature of a finite region of the predetermined cross section and transfer the measured temperature to a control algorithm, wherein the control algorithm is configured to send a modified signal to obtain a predetermined temperature based on the measured temperature; 
 a powder bed having a synchronized motion with respect to the predetermined image area. 
 
     
     
       2. The system of  claim 1 , further comprising a powder reservoir for depositing additional powder layers onto the platform. 
     
     
       3. The system of  claim 2 , wherein the system further comprises a rotating drum combined with the powder reservoir for depositing additional powder layers onto the platform. 
     
     
       4. The system of  claim 3 , wherein the rotating drum comprises one or more grooves. 
     
     
       5. The system of  claim 2 , wherein the reservoir is combined with a synchronized movement of the platform to control deposition of additional powder layers onto the platform. 
     
     
       6. The system of  claim 1 , wherein the projector includes an optical power provided by one of an ultra-high-pressure mercury vapor lamp, a metal halide lamp, a high intensity discharge lamp, a high-pressure sodium lamp, a low-pressure sodium lamp, a light emitting diode or a laser.